Method of producing a guide vane

Abstract

The invention relates to a method of producing a guide vane, the method comprising a step of fabricating at least a portion of a metal body of the guide vane by additive fabrication, with at least one outside surface thereof presenting a plurality of cavities; and a step of filling said cavities with a material of lower density than the metal body in order to form at least one substantially smooth airfoil surface.

What is claimed is: 
     
       1. A production method of producing a guide vane, the method comprising:
 fabricating at least a portion of a metal body of the guide vane by additive fabrication, the metal body including a metal frame surrounding a cellular core including at least one outside surface presenting a plurality of cavities opening to at least one of a suction side or a pressure side of the guide vane; 
 placing the metal body in a mold; 
 filling said cavities with a synthetic material of lower density than the metal body in order to form at least one substantially smooth airfoil surface on at least one of the suction side or the pressure side of the guide vane; and 
 removing the metal body from the mold after the synthetic material has hardened. 
 
     
     
       2. A production method according to  claim 1 , wherein the additive fabrication method is a method of selectively melting a metal powder. 
     
     
       3. A production method according to  claim 2 , wherein said powder is selectively melted by an electron beam and/or by laser. 
     
     
       4. A production method according to  claim 1 , wherein each of said cavities is a cell with a depth having an order of magnitude that is equal to or greater than a maximum width of the cell. 
     
     
       5. A production method according to  claim 4 , wherein said metal body comprises a cellular core and at least one solid peripheral element. 
     
     
       6. A production method according to  claim 5 , wherein said solid peripheral element comprises a leading edge, a trailing edge, and/or at least one connection platform of the vane. 
     
     
       7. A production method according to  claim 6 , wherein said solid peripheral element and said cellular core are formed integrally as a single piece by additive fabrication. 
     
     
       8. A production method according to  claim 4 , wherein said metal body comprises a plurality of zones having different cell densities. 
     
     
       9. A production method according to  claim 1 , wherein at least one of said cavities passes from a suction side to a pressure side of the vane. 
     
     
       10. A production method according to  claim 1 , wherein said material of lower density is a synthetic material. 
     
     
       11. A production method according to  claim 10 , wherein said synthetic material is introduced into said cavities in the liquid state and is subsequently hardened. 
     
     
       12. A production method according to  claim 11 , wherein said synthetic material is introduced into said cavities by injection. 
     
     
       13. A guide vane produced by the method according to  claim 1 . 
     
     
       14. A guide vane according to  claim 13 , wherein said guide vane is a fan guide vane of a fan of a turbofan engine. 
     
     
       15. A fan of a turbofan engine including a guide vane according to  claim 13 . 
     
     
       16. A turbofan engine including a fan according to  claim 15 .